Radio frequency identification well delivery communication system and method

ABSTRACT

A system for communicating with downhole components is provided comprising at least one RFID device configured with an identification code. The system further includes a device conduit extending next to the downhole components and a device propulsion system configured to translate the RFID devices next to the downhole components to facilitate an exchange of information between the downhole component and the RFID device. The device conduit may include a check valve or a turn-around sub depending upon the application. In some cases, the exchange of information may trigger actuation of one or more of the downhole components. A method is also provide comprising providing a device conduit near downhole components, propelling an RFID device near to the downhole components via the device conduit and a device propulsion system, and exchanging information between the RFID device and the downhole components.

BACKGROUND

1. Field of the Invention

Embodiments of the present invention generally relate to radio frequency identification well delivery systems and methods.

2. Description of the Related Art

The following descriptions and examples are not admitted to be prior art by virtue of their inclusion in this section.

Radio Frequency Identification (RFID) technology has been used outside of the oilfield industry for a number of years to provide one-way and two-way communication and identification. However, the technology is gaining increased acceptance within the oilfield industry, primarily in surface oilfield applications such as inventory control (e.g., equipment identification) and to an extent in downhole applications to communicate with tools placed downhole. In current applications, RFID technology is deployed using one of the following approaches:

-   -   Placing a downhole RFID module in the drill string, tubing, or         casing, to identify downhole locations and subsequently         conveying a reader to perform an operation at a specific         location when the correct ID code is identified.     -   Pre-programming a downhole tool that will actuate when an RFID         chip is dropped inside the tubing, drill string, or casing.

The existing approach typically pumps or drops the RFID chips or tags down the tubular. However, this is only possible during specific times and situations. When the well is shut-in, dead, highly deviated or horizontal, an RFID device cannot be dropped down. This is also true for a flowing well (i.e., for a flowing well, dropping an RFID is also not possible or practically feasible). In addition, dropping an RFID device only provides one-way travel down the main bore of a substantially vertical well while pumping an RFID device downhole requires an intervention and interruption of production flow.

SUMMARY

In accordance with one embodiment of a system for communicating with downhole components, the system may comprise one or more RFID devices configured with an identification code (ID code). The system may further include a device conduit extending proximate to the downhole components and a device propulsion system. The device propulsion system may translate the one or more RFID devices proximate to the downhole component to facilitate an exchange of information between the downhole component and the RFID device.

In accordance with one embodiment of a method for communicating with downhole components, the method may comprise providing a device conduit proximate to the downhole components and propelling an RFID device proximate to the downhole components via the device conduit and a device propulsion system. In addition, the method may further comprise exchanging information between the RFID device and the downhole components.

Other or alternative features will become apparent from the following description, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying drawings illustrate only the various implementations described herein and are not meant to limit the scope of various technologies described herein. The drawings are as follows:

FIG. 1 is a schematic view of a downhole well communication system for a vertical well according to an illustrative embodiment of the present invention;

FIG. 2 is a schematic view of a downhole well communication system for a suspended or shut-in well according to an illustrative embodiment of the present invention;

FIGS. 3A and 3B are schematic views of alternative embodiments of components of a downhole well communication system according to an illustrative embodiment of the present invention;

FIG. 4 is a schematic view of a downhole well communication system for a deviated or horizontal multi-zone well according to an illustrative embodiment of the present invention; and

FIG. 5 is a flow chart of an illustrative method for downhole well communication according to an illustrative embodiment of the present invention.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible. In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, “connecting”, “couple”, “coupled”, “coupled with”, and “coupling” are used to mean “in direct connection with” or “in connection with via another element.” As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention.

Referring generally to FIG. 1, in accordance with an exemplary embodiment of the invention, a well system 10 may comprise a well bore 20 extending from the surface of the earth 40 to a formation 50 containing desirable production fluids, such as hydrocarbons, among other fluids. Although the well system 10 is shown as a terrestrial surface well, embodiments of the communication system may also be used in sub-sea applications. Portions of the well bore 20 may be lined with casing 25, although the use of casing 25 is not required. The well system 10 may be completed to facilitate production of the desirable fluids to the surface 40 of the well. The completion may comprise production tubing 30 or tubulars and various downhole components 33 a, 33 b, and 33 c, as well as other completion components.

The downhole components 33 a, 33 b, and 33 c, may comprise a variety of valves, sensors, location devices and other components used in a well system 10. For example, the downhole component 33 a may comprise a formation isolation valve (FIV) used to suspend or shut-in a well (i.e., closing off or preventing communication between the surface 40 and formation 50 via the production tubing 30). Downhole component 33 b may represent an inflow control device (ICD) used to facilitate or control flow between the formation 50 and the interior bore of the production tubing 30 via screens, perforations 27, or an openhole section. Downhole component 33 c may represent a sensor configured to measure a well parameter such as flow rate, temperature, pressure, conductivity, water cut, phase composition, or valve actuation position, among other parameters not specifically identified.

The annulus surrounding the production tubing 30 may sealed with a packer 35, such as a casing packer, swell packer, etc., so that the entire well bore 20 is sealed when the downhole component 33 a is shut or closed (in cases in which downhole component 33 a is an FIV). Packer 35 may comprise one or more pass-throughs for a corresponding number of conduits, such as device conduit 120 a and 120 b. In some embodiments, the device conduits 120 a, 120 b may comprise hydraulic control lines in order to take advantage of standard packer 35 pass-through configurations. Although only device conduits 120 a, 120 b are shown, additional conduits such as hydraulic control lines for valve actuation or fiber optics may also be present, among others.

Device conduits 120 a and 120 b may be coupled to the outside of the completion (in this case shown as production tubing 30) so as to not interfere with the operation of the downhole components 33 a-33 c that are configured to close off the interior of production tubing 30. In some embodiments, device conduits 120 a and 120 b may be run inside of production tubing 30 to facilitate control and communication with various downhole components 33 a-33 c in a flowing well, for example. In still other embodiments, device conduits 120 a and 120 b may be composed of various sections or multiple links and lines. In some cases the links may be created inside of the production tubing 30 walls or extend to the interior bore of the completion.

As shown in this illustrative example, device conduits 120 a and 120 b may be coupled together via a turnaround sub 130. The turnaround sub 130 facilitates a continuous loop of device conduits so that an RFID device 90 may be placed into the system at the surface 40 of the well, flow past the various downhole components 33 a-33 c, and be returned to the surface 40 of the well. For example, this type of system may be used in cases in which an RFID device 90 exchanges information comprising data from a sensor (such as may be represented by downhole component 33 c). The RFID device 90 may comprise a data storage area to store data measured by the sensor 33 c. At the surface 40, the RFID device 90 may be read by an RFID reader 110 and the data extracted or copied for future use related to well operation or analysis.

The RFID device 90 may be placed in a device propulsion system 100 located at the surface 40 of the well system 10. The device propulsion system 100 may be coupled to the device conduits 120 a and 120 b. In some cases, the device propulsion system 100 may be a pump, configured to circulate fluid through the device conduits 120 a and 120 b. The RFID device 90 may be configured in the shape of a pill for example, sized small enough to translate within the device conduits 120 a, 120 b and turnaround sub 130, but large enough to allow for the buildup of a pressure differential between the upstream and downstream ends of the RFID device 90. In some embodiments, the RFID device 90 may comprise a seal (not shown) in order to readily facilitate the creation of the pressure differential. The pressure differential may provide the motive force for moving the RFID device 90 through the device conduits 120 a, 120 b and turnaround sub 130.

The communication system of the exemplary embodiment shown in FIG. 1 allows for an RFID device 90 to travel in two directions as the RFID device 90 interacts with downhole components 33 a-33 c. As RFID devices 90 travel via the device conduits 120 a, 120 b, the downhole components 33 a-33 c may be configured to actuate based upon detection of a specific or unique identification code (ID code) stored in a particular RFID device 90. In some cases, a stored command may also be present in an RFID device 90, such as FIV open, or ICD to 40% flow through, among others, so that actuation of a particular downhole component 33 a-33 c may be achieved without requiring a separate or dedicated communication line to that downhole component. Therefore, exchanging information between an RFID device 90 and a downhole component 33 a-33 c may occur in one direction (i.e., from an RFID device to a downhole component, or from a downhole component to an RFID device) or in two directions (i.e., between an RFID device and a downhole component).

Turning now to FIG. 2, this drawing illustrates another embodiment of a communication system configured according to aspects of the present invention. In this drawing, well system 200 may represent a shut-in or closed well. For example, downhole component 33 a may represent an FIV while downhole component 33 b may represent an ICD or other completion component. This well system 200 differs from the previous well system 10 in that only one device conduit 120 extends along the completion (represented by production tubing 30). Device conduit 120 may be coupled with a one-way valve 230 such as a check valve, located at some position downhole. In this example, an RFID device 90 may be placed within a device propulsion system 100 and travel via a device conduit 120 downhole past downhole components 33 a and 33 b. As the RFID device 90 passes these downhole components, the downhole components 33 a and 33 b may be configure to recognize the ID code of the RFID device 90 or other command information and perform some operation, such as opening, closing, etc.

The one-way valve 230 may be configured to allow the RFID device 90 to pass through the valve and exit into the annulus surrounding the production tubing 30. As a result, an operation may be able to control and communicate (in this example, primarily in one direction) with a downhole component located below a shut-in point, without having to compromise the sealing integrity of a shut-in device, such as may be the case if downhole component 33 a is an FIV.

FIG. 3A shows a schematic illustration of a representative but non-limiting check valve that may be used for one-way valve 230. As shown in this illustrative example, the one-way valve 230 may exit into an annulus surrounding production tubing 30 via a valve exit 235. In some cases, the valve exit 235 may be replaced with a conduit 320 so that the one-way valve 230 exits into the interior bore of the production tubing 30 via a valve exit 325 (see FIG. 3B). Although the one-way valve 230 and conduit 320 are shown as separate components, many different configurations of valves and housings may be used. For example, one method may be to integrate the conduit 320 and valve exit 325 into the housing of the one-way valve 230 or to use other devices and components that facilitate the one-way translation of an RFID device 90 by a device propulsion system 100.

Referring generally to FIG. 4, another illustrative embodiment of a communication system of the present invention may be used in multi-zone and/or horizontal or deviated wells. Multi-zone well system 300 is shown as having a wellbore 20 that extends to more than one formation or more than one zone in a single formation (two formations, each with a corresponding zone are shown in this example). Wellbore 20 extends to formations 52 and 54. The annulus located around production tubing 30 is segmented by open-hole packers 335 b-335 c so that each of the formations 52 and 54 may be independently controlled. Of course, in other situations, cased hole horizontal wells may be separated into various zones using cased hole packers for example. Device conduits 120 a, and 120 b may extend along the completion so that they pass proximate to downhole components 333 a-333 c and 337 b-337 c. Downhole component 333 a may be represented by an FIV while downhole components 333 b-333 c may each be represented by ICDs, among other types of downhole components. Downhole components 337 b-337 c may be represented as sensors. As shown in the drawing, device conduits 120 a and 120 b may be coupled together by turnaround sub 130.

Within the zone defined by open-hole packers 335 b and 335 c and interacting with formation 52, an RFID device 90 may be coded with a specific command for downhole component 333 b. Alternatively, downhole component 333 b may be configured to recognize a particular ID code to actuate during an exchange of information, such as opening or closing or an intermediate step between opened and closed. Further, downhole component 337 b may exchange data representing the amount of water cut entering into the production tubing 30 from formation 52. If the percentage of water becomes too high, another RFID device 90 may be used to close or change the choke setting of the downhole component 333 b so that production can continue from formation 54 with less water contamination or without water contamination from formation 52. In this way, the overall life of well system 300 may be extended.

As with previous examples, the RFID devices 90 may be propelled through the device conduits 120 a and 120 b via a device propulsion system 100 and read at the surface by an RFID device reader 110. If the percentage of water from both formations 52 and 54 rise above a predetermined amount, downhole component 333 a may be closed, shutting in the entire well system 300 or the choke setting may be changed to reduce the water cut. The production tubing 30 may be sealed with casing packer 35 to prevent any fluid flow through the annulus. However, even with the well shut in, RFID devices 90 may be circulated through the device conduits 120 a and 120 b to operate downhole components 333 b and 333 c and/or interrogate and retrieve information from sensors 337 b and 337 c.

Turning generally to FIG. 5, a method for establishing a communication system for a well 500 may be shown by the exemplary flowchart in the drawing. One step of the method may be providing a device conduit proximate to downhole components 510. This may occur when the completion is run or after the well is producing (such as via wireline or coil tubing). The device conduit may comprise a single conduit (for one way translation of an RFID device) or a dual conduit (for two way translation of an RFID device). In some cases, a single conduit may provide two way translation of an RFID device if the distal end of the single device conduit is coupled to a storage area or reservoir so that the propulsion system may push and then pull an RFID device back and forth pass a downhole component.

Another step of the method may be propelling an RFID device proximate to the downhole components via the device conduit and a device propulsion system 520. In some cases, the device propulsion system 520 may be a pump configured to pump fluid through the device conduit. In other cases, the pump may be configured to pump fluid into the device conduit and out from the device conduit.

An additional step of the method may be exchanging information between the RFID device and the downhole components 530. As with the device propulsion system, the exchange of information may be one way, two way, or a combination of both (e.g., one way with some components and two way with others). For example, the downhole components may be configured to read an ID code from every RFID device but only send sensor data to RFID devices equipped to store the information. A single RFID device may control a single downhole component or may control multiple downhole components.

Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the elements listed. The term “or” when used with a list of at least two elements is intended to mean any element or combination of elements and should not be considered as an exhaustive list.

While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations there from. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention. 

1. A system for communicating with downhole components comprising: one or more RFID devices comprising an identification code (ID code); a device conduit extending proximate to the downhole components; and a device propulsion system; wherein the device propulsion system translates the one or more RFID devices proximate to the downhole component to facilitate an exchange of information between the downhole component and the RFID device.
 2. The system of claim 1 in which the device propulsion system is a fluid pump.
 3. The system of claim 1 in which the device conduit further comprises a check valve.
 4. The system of claim 1 in which the device conduit further comprises a turn-around sub.
 5. The system of claim 1 in which the device conduit is a control line.
 6. The system of claim 1 in which the exchange of information detects the ID code of the RFID device and identification of a predetermined ID code triggers actuation of a designated downhole component.
 7. The system of claim 1 in which at least one of the downhole components comprises a sensor and the exchange of information comprises a well parameter detected by the sensor.
 8. The system of claim 1 in which the device conduit further comprises a turn-around sub and the system further comprises an RFID device reader communicatively coupled to a surface of a well.
 9. The system of claim 1 in which the one or more RFID devices comprises at least two RFID devices that each have unique ID codes; and wherein two or more downhole devices are each configured to individually actuate upon detection of a specific one of the unique ID codes during the exchange of information.
 10. A method for communicating with downhole components comprising: providing a device conduit proximate to the downhole components: propelling an RFID device proximate to the downhole components via the device conduit and a device propulsion system; exchanging information between the RFID device and the downhole components.
 11. The method of claim 10 in which propelling comprises pumping a fluid through the device conduit.
 12. The method of claim 10 further comprising actuating a particular downhole component based in part upon the information exchanged between the RFID device and the particular downhole component.
 13. The method of claim 10 in which providing the device conduit comprises running a control line proximate to production tubing during completion of a well.
 14. The method of claim 10 in which at least one of the downhole components comprises a sensor and the exchanging of information comprises exchanging data related to a well parameter detected by the sensor.
 15. The method of claim 10 further comprising propelling the RFID device to a surface of a well after exchanging information with the downhole components.
 16. A system for communicating with downhole components in which at least one of the downhole components is located at a point below a shut in point of a suspended well, the system comprising: one or more RFID devices; a device conduit extending proximate to the at least one of the downhole components located below the shut in point; a device propulsion system configured to propel the one or more RFID devices via the device conduit proximate to the at least one of the downhole components; wherein an exchange of information occurs between the one or more RFID devices and the at least one of the downhole components.
 17. The system as recited in claim 16, wherein the device conduit comprises a check valve and the one or more RFID device translate past the downhole components in only one direction.
 18. The system as recited in claim 16 wherein the device conduit comprises a turn-around sub and the one or more RFID devices translate past the downhole components in two directions.
 19. The system as recited in claim 18 wherein the at least one downhole component is a sensor and the exchange of information comprises data related to a parameter of the suspended well.
 20. The system as recited in claim 16 wherein the exchange of information triggers actuation of at least one of the downhole components. 